Mk 1 Project Zippy. Looking Like a Car.

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Re: Mk 1 Project Zippy. Looking Like a Car.

Postby MrBounce » Mon Apr 22, 2019 4:27 pm

After an Easter Egg hunt and far too much food with the in-laws over the weekend, I had some time this afternoon and did some more fibreglassing on the dashtop. Having tidied the edges up with the Dremel, I set about joining the top and front sections together. Having folding some chopped strand mat over and put a heavy weight on it to retain more of a right-angled shape rather than a flat sheet - makes it much easier to work with. Out came the brushes and resin and under the blazing sun I connected the two bits together. I also laid some big sheets of fibreglass over the top, to make everything a little more uniform and stronger. It needs a bit of sanding and filling to make it less "bumpy" but as it will be covered I won't be spending a huge amount of time on it. I now need to figure out how I shall mount it - I have some ideas but I'll consult a couple of friends as three or four brainstorming is better than one.

When I first installed the wiper linkage and wheelboxes, someone advised me that it was wrong and wouldn't work as they were poking out too far. After looking at some of the early pictures before I stripped the car I could see that I was indeed wrong. Trouble was, I needed a spacer with a hole large enough to accommodate the wheelboxes, and unless from getting one from a specialist, I would need to be creative with what was in the Manroom. I settled on a pair of tie-bar bushes. Trouble with bushes (poly or rubber) is that they compress, so holding them steady whilst drilling would be difficult. The solution was a Jubilee cilp surrounding the bush, giving enough inflexibility that I could pop it into the drill vice. I used a 16mm flat wood bit to drill the hole and they fitted beautifully. A little bit of ingenuity with the plastic "washers" the nut sits on and all looks great. Job done!

Front now joined to top

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Additional fibreglass on the top too.

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Wiper wheelboxes fitted way too high

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Doctored tie bar bushes made ideal spacers and all fits together perfectly. Much more clearance below, too.

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Dash top bunged in place to dry properly whilst I establish how to fit it...

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Re: Mk 1 Project Zippy. Looking Like a Car.

Postby MrBounce » Fri Jun 07, 2019 4:28 pm

Apologies for not posting much recently - I have had a lot on my plate and have simply not had the time to get into the Manroom to do more. I took the week off and spent 2 days cleaning the place up (and boy did it need it), before deciding upon 3 things: Find the bonnet catch and fit it, continue sorting the dash top and also finish off the gearchange assembly.

Having been through various boxes, trays and tins, I found the bonnet catch. Which was broken. Something large and heavy had fallen on to it and had snapped one of the tangs that holds one of the springs. Under tension, this piece had gone "sproing" and disappeared off the end of said spring, which was still miraculously attached to the rest of the apparatus. I did think about replacing the whole the thing, but I am nothing if not resourceful, so I shaped a small (and much thicker) bit of metal and welded it to the remains. It certainly won't win any competitions as my welding is barely passable at best (it took a couple of attempts before I got the settings to work!), but it's nice and strong and nobody's going to look at it that closely... I will get round to cleaning and fitting the catch next time I am in the garage.

Next up was the dash top. Having skewered my hand on some of the very sharp and hard fibreglass, I figured that the dash top I had created would be better off as a mould. As it stood it would never be good enough as it was a bit lumpy despite the fact it's likely to be covered. I then spent about 20 minutes being as careful as possible using all my interior trim panel tools to split the fibreglass from the original buck. Eventually, after much persuasion it came free undamaged. I checked for fit then carefully taped the underside up. I got some more fibreglass resin plus borrowed Tink's bog box of csm offcuts and once again set to work. So far I am about halfway through.

Finally I did get round to fitting the gearshift mechanism properly, including the gear lever itself. I wasn't happy with where the mechanism was siting so I decided to pull it all out. Which all went nice and swimmingly (including the roll-pin!) until I got to the bolt which fits to the gearbox casing. As I have fitted an LCB exhaust manifold, there is not quite enough room to remove it. Much swearing occurred. I loosened off the entire inlet/exhaust manifold assemblies and *just* managed to get the bolt out. When on the bench I tapped the housing to take the KAD Quickshift extension and greased everything up. Fitting really was the reversal of removal this time! Gearstick looks good in place, but typically I had fitted my "old" pair of mounting bobbins as the new ones were of such poor quality they'd split. The ones on there are currently too worn to work properly, so new ones are on the list of things to get.

Finally, I changed the plastic wiper plinths for metal ones once I'd painted them. More soon!

Broken bonnet catch repaired with some ugly welding. I shall do some grinding with the Dremel to clean it up.

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Splitting the fibreglass from the first mould. This took a LOT of patience.

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Checking for fit - it was too lumpy to use so it became the new mould.

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Taped up ready for more fibreglass

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First lot drying out

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The refreshed (bo) selecter ready for fitment...

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...and in place. Nice!

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And metal plinths replaced the plastic ones on the wiper mechanism.

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MrBounce
 
Posts: 528
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Location: Suffolk

Re: Mk 1 Project Zippy. Looking Like a Car.

Postby MrBounce » Sun Jun 09, 2019 3:47 pm

Back in the Manroom again today saw me doing some very minor things but it's all progress. I fitted the pin to the bonnet and followed this up with the bonnet catch and release lever under the passenger side dash shelf. I am certain that it will need some fettling when I come to fit the bonnet properly, but as it's not actually done up properly at the moment, that bit can wait. One thing I do know is that it's going to be all very tight under there!!

Pin fitted to bonnet.

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Bonnet catch fitted loosely in engine bay

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...and cable attached. Seems to work, so I greased up the catch and cable. (Apologies for crap photo)

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MrBounce
 
Posts: 528
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Location: Suffolk

Re: Mk 1 Project Zippy. Looking Like a Car.

Postby goldeneye » Mon Jun 10, 2019 9:04 am

Did you reduce the length of the gear shifter?
Midas Mk II
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Re: Mk 1 Project Zippy. Looking Like a Car.

Postby MrBounce » Sun Jun 16, 2019 4:09 pm

goldeneye wrote:Did you reduce the length of the gear shifter?


No. It's a KAD Quickshift kit similar to the one I had on my Classic Mini about 20 years ago. I'm not entirely convinced that I will keep it as I recall they're a proper pain to get into reverse. That said, I will need a new standard gear stick if I change my mind as it's different.

Not much to report this weekend. I've replaced the gear selector bobbins with brand new poly items and I've done a load more fibreglassing on the dash top. You've seen that before so here's a nice picture of the nice new bobbins:

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Joined: Mon May 16, 2011 9:16 pm
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